The 8 Most Common Multi-Lane Granule Packaging Machine Faults — How Many Have You Encountered?

The 8 Most Common Multi-Lane Granule Packaging Machine Faults — How Many Have You Encountered?

In the daily operation of multi-lane granule packaging machines, some problems recur again and again.

Not because the machine quality is poor — but because many factories don't fully understand their equipment. They can't distinguish between normal phenomena and early fault warnings.

Below are the 8 most common multi-lane granule packaging machine faults, with corresponding troubleshooting methods and prevention measures.

Fault 1: Multi-Lane Metering Cup Desynchronization

Symptom: Fill weights vary between lanes — some bags overweight, others underweight.

Cause: Each metering cup on a multi-lane machine is driven by an independent servo motor. If axis parameters aren't synchronized during calibration, fill weight variation occurs.

How to check:

1. Verify each lane's servo motor parameters are consistent.

2. Weigh each lane's fill using standard calibration weights, record deviations.

3. For lanes deviating more than ±2g, adjust the metering cup stroke parameters in the servo settings.

Prevention: Perform full-lane synchronization calibration when the new machine is commissioned. Re-check quarterly.

Fault 2: Film Deviation

Symptom: During bag formation, film shifts to one side, causing crooked seals or inconsistent bag length.

Cause: Uneven film frame tension, misaligned guide rollers, or inconsistent film thickness.

How to check:

1. Inspect both sides of the film frame tension springs for symmetry.

2. Visually check if guide rollers are in the same plane.

3. Replace with a known-good film roll to rule out film quality issues.

Prevention: After each film roll change, re-adjust tension to moderate — neither too tight nor too loose.

Fault 3: Abnormal Seal Temperature

Symptom: Seal area shows scorching, incomplete sealing, or weak seal strength.

Cause: Temperature sensor drift, heating rod aging, or large ambient temperature fluctuations.

How to check:

1. Use an infrared thermometer to measure the actual sealing roller surface temperature, compare with the display reading.

2. If deviation exceeds ±5°C, contact technicians to calibrate the temperature sensor.

3. Replace heating rods after 2,000 hours of use.

Prevention: Preheat the machine for 5 minutes before startup to stabilize temperature before formal production.

Fault 4: Material Buildup at Discharge Port

Symptom: Material accumulates at the discharge port, unable to flow smoothly into the metering cup.

Cause: Material moisture causing clumping, insufficient vibrating feeder amplitude, or undersized discharge port.

How to check:

1. Check if material shows signs of moisture-induced clumping.

2. Adjust the vibrating feeder amplitude to ensure uniform material flow.

3. Verify the discharge port diameter matches your material particle size.

Prevention: Check raw material humidity before storage, especially during rainy seasons. Clean the vibrating feeder monthly to prevent residue buildup.

Fault 5: Inconsistent Bag Length

Symptom: Bag length fluctuates, accuracy exceeds ±10mm.

Cause: Film feed servo motor belt slipping, encoder signal instability, or film tension fluctuation.

How to check:

1. Inspect the film feed servo motor belt tension — adjust or replace if slipping.

2. Confirm the encoder is securely mounted and signal cables are well-connected.

3. Monitor whether film tension stays within stable range.

Prevention: Check belt tension weekly. Calibrate the encoder monthly.

Fault 6: Abnormal Noise

Symptom: Irregular sounds during machine operation.

Cause: Lack of lubrication on transmission parts, worn bearings, or foreign objects entering moving components.

How to check:

1. Listen to locate the general source of the noise.

2. Inspect lubrication on all transmission points — top up as needed.

3. Open protective covers and check for foreign objects jammed in moving parts.

Prevention: Lubricate every 500 operating hours. Inspect transmission components monthly.

Fault 7: Material Debris in Seal Area

Symptom: Material particles trapped in the seal area, causing weak seals or unsightly appearance.

Cause: Residue in the metering cup outlet, misaligned dropping position, or dust on the film surface.

How to check:

1. Clean residual material from the metering cup outlet and dropping tube.

2. Adjust the dropping position to ensure material lands in the bag center, away from the seal area.

3. Check if the film roll surface has dust — install a dust removal device if needed.

Prevention: Perform thorough cleaning and material clearance whenever switching product recipes.

Fault 8: Touchscreen Freeze

Symptom: Touchscreen becomes unresponsive or restarts frequently.

Cause: Unstable voltage, software bug, or loose touchscreen cable.

How to check:

1. Verify factory voltage stability — install a voltage stabilizer if needed.

2. Restart the machine and observe if the issue recurs.

3. Check if the touchscreen ribbon cable is securely connected.

Prevention: Ensure the machine uses a dedicated power circuit, separate from high-power equipment.

Quick Reference: Fault → Cause → Prevention

When to Contact After-Sales Support

Contact ZSYAN technical support immediately if:

• Troubleshooting exceeds 30 minutes without identifying the issue

• Hardware failure involves servo motors or PLC controllers

• The same fault recurs repeatedly, indicating a systemic issue

• The machine has exceeded 2,000 operating hours without comprehensive maintenance

ZSYAN provides 7x24 remote diagnosis via WhatsApp and email. Overseas customer spare parts ship from China or regional warehouses within 48 hours.

FAQ

Q1: How often should a comprehensive maintenance be performed on a multi-lane granule packaging machine? Recommended every 2,000 operating hours: lubricate transmission parts, inspect servo motor status, calibrate metering system, replace worn components. Daily inspection (per shift): check lubrication, cleanliness, and abnormal noise.

Q2: How do I fix desynchronized multi-lane metering? Weigh each lane's fill using standard calibration weights and record deviations. For lanes deviating more than ±2g, access the servo parameter settings and adjust stroke parameters. Full-lane synchronization calibration is recommended when the new machine is commissioned.

Q3: What should I do if seal temperature fluctuates frequently? First, use an infrared thermometer to measure the actual sealing roller surface temperature and compare with the display. If deviation exceeds ±5°C, contact technicians to calibrate the temperature sensor. Replace heating rods after 2,000 hours of use.

Q4: What causes frequent discharge port blockage? Most common causes: material moisture clumping and insufficient vibrating feeder amplitude. Check raw material humidity, especially during rainy seasons. Adjust the vibrating feeder amplitude to achieve uniform material flow.

Q5: How do I handle frequent touchscreen freezes? First, check factory voltage stability — install a voltage stabilizer if needed. Second, check if the touchscreen ribbon cable is loose. If the issue persists, the software version may be outdated — contact ZSYAN for firmware updates.